O`Brian - Model Autocover II-CH - Tarping System - Manual

1 $4.00 Diablo TARPER US Patents and Patent Pending Owner’s Manual FOR ASSISTANCE CALL 252-291-2141 ATTENTION DISTRIBUTOR: DO NOT DISCARD, Please forward to customer Along with warranty registration when unit is delivered and hang driver operation Hang tag in cab around hoist controls WARNING: If incorrectly used, this equipment can cause injury June 2008 2 TABLE OF CONTENTS Section Description Page No. Part 1 Operation 2 Part 2 Overview 3-4 Part 3 Diablo Packing List 5 Part 4 Gantry Installation 6-7 Part 5 Modular Installation 8 Part 6 Side Arm Installation 9 Part 7 Plumbing 10-12 Part 8 Final Adjustment & Maintenance 13-15 Part 9 Warranty 16 COVER OPERATION TO COVER: 1. Raise side arms and extend upper arms to raise roller up between cab and container. 2. Raise gantry above container (OPTIONAL). 3. Once the roller is past the front of the container, continue to hold valve in the covering direction and cover container. 4. Position the roller so it will REST ON THE TOP REAR EDGE OF THE CONTAINER BUT BELOW 13’6”. POWER DOWN THE ROLLER AGAINST THE TAILGATE. This helps to keep the roller from bouncing up and down against the container while going down the road. If powered against the tailgate, the roller should ride tightly against the container as the truck goes down the road. 5. If over height, rotate arms until roller rests against hoist rails and power down. 6. Flip the tarp side flaps down and secure them as needed. 7. Lower gantry down to just under container edge (Optional). TO UNCOVER: 8. Un-secure the side flaps. 9. Extend the upper arms to get roller off of container or hoist rails. 10. Bring the side arms forward and clear the front top edge of the container with the roller. 11. Lower gantry (OPTIONAL). 12. Lower the side arms and adjust the upper arms in order to lower the roller down between the container and the cab. 13. POSITION THE ARMS SO THAT THE WEIGHT OF THE ROLLER IS RESTING ON THE BOTTOM OF THE CRADLE AND NOT ON THE ARMS This keeps the arms from bending downward. 3 4 DIABLO CRATE CONTENTS Quantity Part Number Name or Description 2 MBD Mounting Brackets 4 SF4 Gussets for Brackets 2 ROAC Rotary Actuators 2 LPD Linkage for Diablo 2 DLA Lower Side Arms 1 CCUA-DR Upper Side Arm-Drivers Side 1 CCUA-PA Upper Side Arm-Pass Side 2 DUR Cradle Uprights 1 RSA-A w/Tarp Roller with Aluminum shaft & tarp attached 1 CRADLE Cradle 2 CD200115 Upper Arm Cylinders 1 SAEXLPS-D Stabilizer Bar for Diablo 4 JF038 Steel Hydraulic Lines 1 HOSEKIT-D Hose Kit for Diablo 1 SPK-D Diablo Small Parts Kit 1 D/TB Tarp Bar 5 GANTRY INSTALLATION 1. Check for clearance between cab, exhaust, and hoist. 2. You need a minimum of 8” clearance between hoist and cab to mount the gantry. 3. Sit gantry on top of chassis, remove any of the bolts that are in your way and mark the mounting bracket for these holes. Drill a minimum of 2 holes in the mounting plate so that you can use the pre-existing holes for gantry mounting. If no holes are available, new holes will need to be drilled. If this option will not work then a chassis bridge will need to be fabricated for gantry attachment. 4. The closer the roller is to the cab the easier it will be to raise and lower arms. *Note- leave a minimum of one (1”) inch clearance between cab and gantry. 5. Measure the distance from hoist to gantry. Make sure both gantry legs are the same distance from the hoist and plumb. 6. Mount the cradle on top and center of gantry using the 4) ½” x 1 ¾” bolts. Insert the rubber shims between cradle and gantry uprights. These shims are needed to allow for chassis flex. Be sure to mount the cradle with the ½” bolts and Cradle Reinforcement #HYAEC7 from the top and the locknuts on the bottom. Do not over-torque mounting bolts and squish out bushing. Over-torquing bolts will cause cradle to crack and void warranty. Snug bolts down until shim starts to deform into cradle slot. This should be enough torque to locate cradle to gantry. 7. Place roller assembly into the cradle with the end marked PASSENGER SIDE and TORQUE SHAFT on the PASSENGER SIDE. Roll the tarp and tarp bar off of the roller and bolt the tarp bar to the BACKSIDE of the gantry in the provided holes using the 3/8” x 5”bolts and locknuts. (See Diagram) You will need to drill the holes in the tarp bar. ( Not Pre-Drilled) 8. NOTE: The shaft end on the passenger side has a FLAT spot. So you can put the supplied wrench on for tensioning. 6 7 MODULAR INSTALLATION NOTE: The installation of the Diablo Modular is very simple. The only thing involved is mounting the rotary actuators to the truck’s sub-frame. 1. Federal D.O.T. allows for 108” overall width for safety devices. Therefore; maximum width for the Diablo Tarper must not exceed 108” overall width. This includes any bolts, nuts, hydraulic fittings, etc. Check with your state and local D.O.T. to determine what standards apply in your area 2. For example, if the hoist is 35 ½” wide, then the following formula will give you your maximum overall width, if it is agreeable with your local D.O.T. 108”-35-1/2”=72-1/2” 72-1/2” divided by 2 = 36-1/4” maximum width from hoist for each side. O’Brian recommendation is 36” for each side 3. PIVOT POINT LOCATION: Due to the rotary actuator’s width, a standard pivot point will not work. But due to the actuators 180 degree capability, we can mount the actuator in a better, more ideal location. You can place it in front of the first wheel,if that is close to center. If it is not close to center, then you will have to move the actuator between the wheels, closest to the centerpoint. 4. The Rotary Actuators are not side sensitive; however the splines are located in mid-rotation and need to be rotated all the way to the front of the truck before sliding on or torquing down the linkage assembly to the spline adapter. The modules must be square side-to-side, and parallel to the hoist. They must be set up so that the arms will fall into the cradle and not stop just before it. If a slanted installation is needed to match fender profile, then mount the actuators in 60 degree increments and allow for the roller to completely fall into and be supported by the cradle See Diagram 8 Due to the splines of the actuator, the actuator MUST be mounted in 60 degree increments to allow for the arm to run parallel to the ground and to allow for enough arm rotation to cover a 22’ 40 cu.yd.box. 5. As a general rule, mount the actuators as low as possible to clear the container. 6. Use the supplied 3” x 3” tubing for mounting the actuator. You may have to cut the length to get the actuator out to but not past 108”. DO NOT WELD TO THE CHASSIS THERE MUST BE A PLATE BOLTED TO THE CHASSIS OR USE THE HOIST SUB FRAME TO WELD TO. 7. Before the tubing has been welded, you must orient the actuator mounting plate. This is the 7”x7”x1/2” metal plate with 4- ¾” holes in it. Be sure to orient the plate with the finished edge to the top of the actuator. Tack-weld the mounting bracket in place and mount the actuator with the ¾” bolts and lockwashers. Check for clearance between tires, containers, etc. Once you are sure of the installation, burn in the welds, add the gussets under and beside the tubing, and torque the ¾” bolts to 150 ft/lbs. 8. Use the supplied gussets to finish the actuator installation. A gusset must be welded under and to the side of the tubing to give vertical , lateral and torsional support to the actuator mounting bracket(s). 9 SIDE ARM INSTALLATION 1. Slide the linkage pivot onto the spline of the actuator. Be sure that the spline has been rotated completely forward BEFORE torquing down the spline retaining bolt. If not then you will need a gear puller to remove the linkage from the spline. Factory Recommended coating of splines with anti-seizing before installing 2. Mount the spline retaining washer over the spline with the 3/8”x 1 ½” bolt. Snug down and then torque to 30 ft/lbs. 3. Slide the lower arm (DLA) into the linkage pivot (LPD) 4. Slide the upper arm (CCUA-DR/PA) onto the shaft of the tarp roller (RSA) 5. Slide the lower arm out AND rotate the upper arm around so that the pivot holes are aligned. 6. Ideally, the arms should be at a 90 degree angle. This will allow the arms to be below and in front of the containers, almost eliminating any arm damage. 7. Attach the lower arm to the upper arm using the 1”x3 ¼” steel pin with a ¼” hole drilled on one end. Secure the pin to the arm with the ¼” bolt and lock nut. 8. Make sure that the lower arms are level. Slide the lower arm in or out of the linkage assembly to accomplish this. When level, measure the distance from the elbow pivot to the linkage assembly. Make sure that both sides are the same distance and level before drilling. IF you cannot 10 level the arms, then try to get the upper arm running perpendicular to the ground. 9. Drill and bolt the lower arm to the linkage assembly using the provided hole as a guide. Secure the lower arm with a 3/8” x 3” bolt. 10. Align the rod end of the 12” stroke cylinder with the lower hole in the upper arm and insert the provided 1” x 3” steel pin with a ¼” center drilled hole. Rotate until the holes line up and secure using a ¼” bolt and locknut. Rotate the cylinder barrel until the hydraulic ports are facing the ground 11. Extend the cylinder by hand and attach the base of the cylinder to the 1”x3” clevis pad with the 1” x 2 ½” pin and cotter pin. 12. Place enclosed tarp tensioning wrench on passenger side RSA-A shaft. Torque set screw against the flat side of RSA-A shaft. Torque the wrench 10-12 turns clockwise. Finish by aligning the arm hole with the roller hole and placing a 5/16” x 1 ¾” bolt through roller shaft and upper arm on Passenger and Driver sides. Finish by tightening the 5/16” locknuts against the upper arm. 13. PRACTICE EXTREME CAUTION THE WRENCH COULD SLIDE OUT OF YOUR HANDS, SPIN AROUND AND BREAK WRISTS 14. Install the stabilizer bar (SAEXLPS-D) between the upper arms as shown. 11 DIABLO PLUMBING INSTRUCTIONS 12 *Hydraulic systems that flow over 50 gpm, require a higher flow Priority valve. (OPT.) *Hydraulic systems over 3000 psi require a higher pressure Priority valve. (OPT.) or require mounting priority valve downstream using power beyond Plumbing Instructions 1. Mount the tarper control valve where it is easiest for the driver to operate but out of the way of the tarper arms. 2. Mount the Priority valve at a place that is easily accessible for hydraulic lines and maintenance. 3. Disconnect the pump line from the hoist control valve. 4. Plumb the pump line into the 1” o-ring port labeled “P”. 5. Plumb from the 1” o-ring port labeled “BF” back to the hoist control valve (Not Supplied) 6. Plumb from the ½” o-ring port labeled “CF” to the relief valve side of the tarper control valve. (Not Supplied) 7. Plumb from the return side of the tarper control valve back to tank.(Not Supplied) Actuator Plumbing Instructions 1. Screw the 2-1/4” “T’s” into the actuator ports 1 & 3 2. Screw the 2-1/4” elbows into ports 2 &4 3. Have the fittings for ports 1&2 slightly offset from center and the fittings for ports 3&4 more offset than 1&2(See drawing). 4. The ¼” steel lines are side sensitive. Match the offsets of the tubing with the offsets of the fittings or vice-versa. 5. Screw the steel lines onto the fittings but leave loose. We will tighten later when bleeding the system. 13 UPPER & LOWER ARM PLUMBING INSTRUCTIONS 1. Screw 4- 3/8” Tee’s onto one end of the 4- 3/8” steel lines. 2. Route the 4- 3/8”steel lines down the chassis in a neat manner. Be sure to use the weld/plastic tabs to secure the 3/8” steel lines to the sub assembly, with the T’s toward the rear of the truck (See Diagram) 3. Install the flow restricted 6/8 fittings into the control valve for the actuators. (See Diagram) If the standard 6/8 fittings are used instead of the restricted 6/8 fittings, the actuators will rotate extremely fast and result in uncontrollable arm behavior. THIS MAY RESULT IN DEATH OR SERIOUS INJURY 4. Install the standard 6/8 fittings into the control valve for the upper cylinders. 5. Route the (4) #4 hoses from the control valve work ports to the (4) 3/8” steel lines. 6. Route the (2) #1 hoses from the #1ports of each actuator to the same T. (See Diagram) 7. Route the (2) #1 hoses from the #3ports of each actuator to the same T. (See Diagram) 8. Route the (2) #3 hoses from the base of each upper cylinder to the same T. Be sure to put the short protective sleeving on the hose when it exits the arm to the cylinder. Put the longer protective sleeving on the hosing where it enters the arm. Route the hosing over the pivot and through the tubes of the actuator. (See Picture) 9. Route the (2) #3 hoses from the rod end of the upper cylinder into the arm, around the pivot, through the tubes of the actuator and to the remaining T. Be sure to put the shorter protective sleeving on the hose where it enters the arm at the cylinder and the longer sleeving on the hose where it exits the arm and wraps around the pivot. 10. Tighten the actuator hose fittings against the brass Tees. Leave the steel lines loose at the elbows. 11. Start engine and engage the PTO. Start rotating the lower arms. IF the arms start to rotate-STOP and make sure that the lines are loose and leaking oil at the fittings. If not then loosen fittings and make sure air is out of system. If leaking fluid, tighten fittings. 12. Once sure all air is out of system, bleed upper arm cylinders. 13. Once upper arms are bled, rotate arms COMPLETELY to the rear. Once completely rotated, start to rotate back to front. If arms start to move, STOP. Check that fittings are loose and oil is bleeding. If not then loosen and bleed system. If bleeding, tighten fittings and rotate arms back to front of truck. 14. It is very important that all of the air is bled out of the rotary actuators. If not then the arms will slam resulting in possible arm damage. 11. Protective sleeving MUST be installed wherever a hose enters or exits an arm. 14 FINAL ADJUSTMENTS 1. Bleed all hoses and check all fittings and lines for leaks. 2. If arms do not move smoothly; re-bleed lower cylinders and re-bleed upper cylinders. 3. Stick caution labels and operation labels where driver will be sure to see them. Hang driver’s operation tag in cab around hoist controls. 4. Fill out warranty application and put with installation manual in cab for customer. MAINTENANCE 1. If arms will not extend or retract, check that the hydraulic pressure for the tarp valve is set at 2350 psi, and that the overall pressure relief is set at 2500 psi by using the gauge port on the diverter valve. The port is labeled with a stamping of “G”. 2. Check for hose abrasion on a weekly basis. Repair or replace as needed. 3. Adjust spring tension if tarp is slack or will not roll up. OPERATOR TIPS 1. Do not operate under or near electrical wires. 2. Keep clear of moving parts. 3. Do not allow anyone on container when unit is in operation. 4. If arms stop moving, they may have hit debris in the container. Reverse arm movement, re-adjust trash/ re-adjust arms, and recover. This shows that the tarper relief valve is working properly. 5. If cover rolls to one side when rolling up it is because of one of several things Arm is bent- straighten arm Upright is not plumb, straighten upright. Side arms are not parallel to frame/hoist. Realign bracket Actuators/Cylinders have air in system/ Actuator/Cylinder bypassing. Bleed system/ rebuild Actuator/Cylinder. Cover not square at one end or both. If not square, unroll cover and 15 remove RSA-A tarp clamp on end of tarp that is rolling up slack. Pull excess cover under clamp and re-attach. Wind is blowing tarp in from side. Move truck into the wind. TARP REPLACEMENT OPTION 1 “Most Economical “ 1. For Option 1, you will need to purchase the TARP WRENCH, p/n LW from O’BRIAN. 2. Operate the tarp system and extend the roller out to it Lowest and farthest position, without a box on the hoist. Possition the roller about four feet off the ground. 3. With the aid of a second person, unroll the remaining tarp off the roller and position the “Locking Wrench” so that you can easily remove the old tarp and install the new tarp. 4. Slide the TARP LOCKING WRENCH into the slot on the end of the roller and slowly release the tarp until the Wrench handle is pressed against the stabilizer bar. 5. Remove screws and tarp clamp from roller. Remove old tarp from Cradle by removing the two bolts holding the tarp bar inside the front sleeve of the tarp. 6. Discard the old tarp. Spread out the new tarp onto hoist with the O’BRIAN logo up and close to the Cradle. 7. Re-insert the tarp bar into sleeve of tarp. Center the tarp on the tarp bar and re-attach tarp bar to Cradle. 8. Attach rear end of Tarp to Roller with the Tarp Clamp and Screws. Make sure the tarp is centered. 9. With the aid of a second person, pull on tarp to release the pressure from the wrench. Re-move the wrench. Gradually ease the tarp onto the Roller and make sure that the tarp rolls up and that the flaps are folded up under the tarp as it rolls up. 10. Operate the tarp sysstem and place the roller back into the Cradle. ***Note*** If spring pressure is lost, re-tension roller from the FRONT OF THE TRUCK ONLY See pretension directions earlier inthebook. DO NOT TRY TO RE-TENSION ROLLER FROMREAROF TRUCK AS THE SPRING TENSION AT THE REAR IS FAR TOO GREAT*** 16 TARP REPLACEMENT OPTION 2 “Most Time Consuming” 1.Remove Roller from between Arms and remove old tarp. 2.Spread new tarp on floor with the O’BRIAN logo up and flaps down. (SeeDiagram). 3.Position Roller on top of tarp,6”-9” from edge of tarp, at the opposite end of the O’BRIAN logo. 4.The roller shaft will have a machined flat edge on one end. This is the passenger side. Be sure that the passenger side of the roller is on the passenger side of the tarp (opposite end and opposite side of the O’BRIAN logo. 5.Place the end of the tarp around and on top of the roller. Attach the tarp to the roller using the tarp clamp and screws. Use the existing holes if possible. If you have to create new holes, attach the screws on the opposite side of the spring bolt sticking out of the roller. 6.Slide the tarp bar into the sleeve of the tarp and mount back into the Cradle. Make sure that the tarp is centered left to right. 7.Roll tarp tightly around the roller and roll tarp onto roller. 8.Place the Roller into the Cradle with the sleeve and tarp bar coming over the top of the roller and attaching to the Tarp Bar. 9. See Tensioning Roller below. 17 Pre-Tensioning Roller 1. Lay ROLLER AND TARP INTO CRADLE. ***Note***ONLY PRETENSION WITH ROLLER IN CRADLE*** 2. Slide Driver’s side arm onto the 1” roller shaft. 3. Attach the tarp-tensioning wrench, part number CRANK-C4 (provided in kits) to the Passenger side’s 1” roller shaft. Tighten the wrench screw down tight onto the machined flat surface on the 1” shaft. 4. FIRMLY HOLD ONTO TARP TENSIONING WRENCH FAILURE TO DO SO WILL CAUSE BODILY INJURY 5. Torque the wrench 9-11 complete turns clockwise to pre-tension the roller spring. After you torque the shaft the 9-11 turns, turn the shaft clockwise looking for the hole alignment on the driver’s side. Insert the bolt back into the driver and passenger arm and the roller shaft. 6. Remove the wrench from the roller. 7. Install the stabilizer bar onto the driver and passenger arms. 8. Operate the tarp system to check system. a. Does it have enough spring tension to roll tarp up? No, repeat procedure. You might have to add 1-2 additional turns to roller shaft. Does it roll the tarp straight in or does it roll to one side? (This test is with the arms moving together.) If the tarp rolls to one side with the arms moving together, then you need to remove the slack in the tarp, so that the tarp will roll up even on the roller. If the tarp does roll to one side, then you will need to remove tarp slack. Remove screws from center to end of tarp clamp on slack side of tarp. Slide the excess tarp past the tarp clamp to remove the excess tarp and then re-screw the tarp down. Now try it again. 18 DECALS Item Part Number Part Description Quantity 1 UD13 Electrocution Decal 1 2 Serial Serial Number Plate 1 3a Label Operate 5 Control Instructions-Joystick 1 3b Label Operate 6 Control Instructions-Gantry 1 5 Warning Pinch Point Warning Decal 2 6 RTC Roller Spring Tension Decal 1 7 Diablo Diablo Decal 2 8 Hanger Driver Operation Hanger (Place in Cab) 1 9 Manual Owners Manual (Place in Cab) 1 10 Warranty Warranty Application (Place in Cab) 1 19 20